Chartek Application Training

Technical Service For ChartekFire Proofing Intoduction

Chartek Fire Proofing Introduction / Training

Chartek Introduction

To show differences between PC paint products, applications, equipment, against Chartek fireproofing applications, equipment.

Chartek Training

To be carried out by International Chartek Technical Service Chartek applications with dedicated PC Technical Service Personnel, competent to carry out an Chartek Field Audit Report in compliance with the Chartek Audit programme.

CHARTEKAgenda For Training

• Introduction• Chartek Materials• Application of Chartek 7:

– Surface Preparation

– Priming

– Masking

– Application ( 1st coat , 2nd coat )

• Final Inspection• Top coating

Introduction and Product Background

• Over 30 years of oil, gas, petrochemical and power generation experience

• Chartek 59, the world’s first epoxy intumescent material developed out of the NASA Research Programme

Chartek Materials – 59, 3, 4, 7.

Over 30 years track record and experience, backed up by International Paint Ltd

CHARTEK 1709:

• Advanced Chartek technology, qualified by Underwriters Laboratories (UL) ANSI/UL 1709 Exterior Listing

Chartek

DefinitionDefinition:

Chartek is a reinforced intumescent epoxy system, supplied in a two component kit

Base : Base : Epoxy

Curing Agent : Polyamine

Method of Protection :Method of Protection : Intumescent

Reinforcement :Reinforcement :

Generally : Patented hybrid carbon glass fibre mesh named HK-1

Specific Projects : Metal mesh (weld mesh/hardware cloth)

Base/Cure Packaging

Chartek 7 Chartek 1709 Chartek 8

50 Kg Kit

Standard Plural Kit

Part A: 35.48kg

Part B: 14.52kg

Part A: 35.7 kg

Part B: 14.3 kg

Part A: 35.7 kg

Part B: 14.3 kg

20 Kg Kit

Single leg / Premix Kit

Part A: 14.20kg

Part B: 5.80kg

Part A: 14.3 kg

Part B 5.7 kg

Part A: 14.3 kg

Part B 5.7 kg

50 Kg Kit: 20 Kg Kit:

Chartek Ratio Range

Chartek 7 Chartek 1709 Chartek 8

Part A:B as a ratio by volume 2.33:1 2.33:1 2.33:1

Part A:B as a ratio by weight 2.45:1 2.5:1 2.5:1

Maximum acceptable ratio 2.56:1 2.61:1 2.61:1

Minimum acceptable ratio 2.32:1 2.37:1 2.37:1

INTUMESCENCE

• Chartek will react, intumesce and is dependent on a heat source

• The swelling mechanism is known as Intumescence

• The intumescent reacts in strata, inner layers

progressively reacting as the heat penetrates the outside layer

Stage 1: Initial fire Exposure

Unreacted Material

Substrate

Fire

INTUMESCENCE

– Stage 2: Short term fire exposure

Char

Reaction Zone

Unreacted Material

Substrate

Fire

INTUMESCENCE

– STAGE 3: Mid term fire exposure

Char

Reaction ZoneUnreacted Material

Substrate

Fire

INTUMESCENCE

» STAGE 4: End of fire term

Char fully reacted

Substrate

Fire

INTUMESCENCE

INTUMESCENCE – CHAR FORMATION

General Application Procedure

Surface Preparation

Priming

Masking

1st coat + Mesh installation

2nd coat

Final Inspection

Top Coat

• Make certain good bond between primer and substrate

• Make certain good bond between primer and Chartek

• Make certain clean surface to ensure optimum bond between Chartek /primer/substrate

Surface Preparation

• Dry Blast Cleaning (Main) - Surface shall be free of all visible oil , grease , dust , dirt millscale , rust , oxides - Sa 2½,SSPC SP10,NACE No.2 - Blast Profile ( Carbon Steel ) must be 50 to 75 microns ( 2 to 3 mils ) profile

< Note > - Stainless Steel Non-metallic abrasive should be used and a profile of 35 to 50 microns is required - Aluminium Non-metallic abrasive should be used and a profile of 75 to 100 microns is required

Surface Preparation

Surface Preparation

• Power Tool Cleaning - Power Tool Cleaning is not generally an acceptable method for preparing metal substrates for either primer or Chartek application. However , it may used for small areas of repair ( typically not exceeding 1 ㎡ , for example welds and local repair areas ) - SSPC SP3

Purpose of Primer - Holding primer : To prevent corrosion formation prior to

overcoating with Chartek

- Correct primer type and thickness are required to achieve strong bonding

of Chartek to the substrate

Applied epoxy primer ( Intergard 269 ) Applied epoxy zinc primer ( Interzinc 52 )

Priming

PRIMER TYPE ALLOWABLE THICKNESS

a) Epoxy Polyamide Up to 75 microns with 100 microns allowed in small overlap areas

b) Zinc Silicate Up to 75 microns maximum

c) Zinc Rich Epoxy Up to 75 microns maximum

PRIMER QUALIFICATION – PRIMERS TYPES AND THICKNESS

b) or c) with epoxy tie coat 110 microns dft total system maximum

b) or c) up to 75 microns tie coat not to exceed 40 microns

125 microns total system allowed in small overlap areas


• Epoxy polyamide• Zinc silicate• Zinc rich epoxy• Zinc silicate and tie coat

• Zinc rich and tie coat

• Aluminium epoxy (surface tolerant)

• Moisture tolerant

MANUFACTURERS’ DATA SHEETS AND RECOMMENDATIONS APPLY

PRIMED SYSTEM MUST BE FULLY CURED PRIOR TO OVERCOATING WITH CHARTEK


• Sheeting for weather protection/environment maintenance

• Masking for termination of Chartek

• Instruments, gauges, Electrical conduits etc

Masking

• Check points prior to application

a. Ambient Conditions - Air temperature : minimum 5 ℃ - Relative humidity : 85% - Surface temperature : at least 3 ℃ above dew point temperature

b.Material Preheating - In order to make a good spray pattern and work efficiency, the material should be preheated ( 100% volume solid ) * 30 to 34 for 24 hours ( maximum 48 hours )℃ prior to use - Accelated overheating may undesirable changes to its properties ( including shorter pot life )

Application ( Plural spray equipment )

c. Plural Spray Equipment preparation - Machine must be placed at clean and warm area - Prior to use , machine should be fully pre warmed

- All pressure,gauge,valve,coupling,hose,gun should be checked during warming

Application ( Plural Spray Equipment )

Operating parameters for plural component spray machines

d. Ratio Check - When all preparation are finished , Ratio Check should be performed before spray work - As a minimum , Ratio Check by weight should be performed at the start up of each day’s production and again if the machine is shut down and restarted for any reason - Constant checking of the displacement pump pressure gauges and the color of the mixed Chartek should be carried out by the machine operator and sprayer respectively


< Ratio Check Procedure >

A. Weigh clean empty Part A and B containers and note the respective weights B. Place the containers under the ratio check drain valves and open the valves at exactly the same time C. Close the valves when the containers are at least half full at exactly same time

D. Find the net weight of each part by subtracting the weight of the containers E. Calculate the ratio of Part A to Part B as a percentage of the total weight

Example…. - Part A empty container weight : 1.3kg , Part B empty container weight : 1.3kg - Part A full container weight : 15.3kg , Part B full container weight : 7kg

- Part A net weight : 15.3kg-1.3kg = 14kg , Part B net weight : 7kg-1.3kg = 5.7kg

- Part A / Part B : 14kg / 5.7kg = 2.45 , Ratio by weight = 2.45 : 1


Ratio Check Progress

Prepare empty containers Weigh and note the weight

Drain materials at least half Calculate the net weight


• 1st coat + Mesh installation a. Spray

- In order to make a good fan , enough pressure and temperature

proper spray tip should be needed

* Recommended Tip Size : 0.035” ~ 0.041”

- Sprayer have to check wet film thickness frequently for

specified thickness and even surface

b. Trowelling

- Trowelling helps to ensure good wetting to substrate and

even thickness

- To make sagging,slumping surface evenly


c. Mesh Installation

- Cut mesh to reqired sizes before starting application

- Apply mesh to wet Chartek at approximately

- Roll the mesh thoroughly into the wet Chartek with short

nap rollers dampened with solvent

- Overlap adjacent pieces of mesh by at least 50mm(2”).

For jet fire application, overlap by at least 150mm (6”)

- After installing HK-1, either continue to build up the required

thickness or spray a light coat of Chartek over the mesh to

leave a good key for subsequent coat

- For jet fire application the minimum overlap shall be 150mm

and the HK-1 shall cover all surfaces ( 100% coverage )


Subsequent coat ( Overcoating )• Optimum

– Wet on wet– Within 12 hours– Holding coat (spray surface) to be applied if unable to complete

specified thickness within working shift

• Acceptable– 12-24 hours, checking that the surface is not contaminated/amine

bloomed

• With Care– 24 hours upwards - thoroughly check surface for

contamination/amine bloom. If necessary, solvent wipe/sweepblast


Progress ( 1st coat + mesh installation ) a. Spray

A good fan makes the even surface and thickness

b. Trowelling

Makes the even surface and good wettability to the substrate


C. Mesh Installation

After trowelling,Mesh install with a proper mesh overlap ( 50 mm , 150 mm )

b. Stipple Holding Coat

- Make the rough surface and prevent contamination of mesh - Extend overcoating interval


• 2nd coat a. Spray - In order to make a good fan , enough pressure and temperature proper spray tip should be needed * Recommended Tip Size : 0.035” ~ 0.041” When the spray fan is poor , air pockets on the rolled surface will be occurred due to roughened surface - Sprayer have to check wet film thickness frequently for specified thickness and even surface b. Trowelling - Trowelling helps to ensure good wetting to substrate and even thickness - To make sagging,slumping surface evenly - To reduce the formation of air pockets


c. Rolling

- To achieve a uniform thickness

- To produce smoother surface preventing trowel marks and

high points

d. Stippled finish


Progress ( 2nd coat , Stipple finish ) DFT Check before Next Coat

In order to make a specified DFT , DFT check should performed before next coat

a. Spray ( 1st coated area )


b. Trowelling

Make the even surface and good wettability to substrate

c . Rolling

Make the flat surface with a big roller at the big area Make the flat surface with a small roller at corner,edge


Application

• Check Point - Coated area should be followed to design needed - DFT should be followed to a specified DFT

- Discontinuities,pinholes,voids,mesh showing are acceptable - Debonding,gap at termination are not allowed - Surface should be regular shape and smooth

Final Inspection

< Thickness Measurement > a. Method of measuring DFT - Drilling Check with pin gauge - Using an electromagnetic gauge b. Measurement Criteria Location - Thickness measurements should be taken randomly over coated area - It is recommended that no thickness measurements are taken within 25mm of the edge of structural sections and divisions or within 25mm of the join of flange to web Frequency * " I " sections , tee sections , channels - Webs : 2 readings per meter length on each face - Outer flanges : 2 readings per meter length on each face - Inner flanges : 1 reading per meter length on each face

Final Inspection

* Square or rectangular angles and hollow sections - 2 readings per meter length on each face * Circular hollow sections - 8 readings per meter length spread evenly around the section

* Division and large flat plates - 2 readings per 1 ㎡

Acceptance Criteria

- In all cases , the average thickness must be the specified design or certified thickness

- Unless specifically stated in the project documentation , the minimum acceptable thickness at any point shall not be less than 85% or the design or certified thickness up to a maximum 0f 1.5mm less than the design or certified thickness

- Where any single thickness reading is found to be less than the 85% or 1.5mm criteria of the design or certified thickness , a further 3 readings shall be taken within a 300mm radius of the low reading.That area shall be brought up to the required thickness

Final Inspection

• Chartek will be topcoated to meet owner’s colour schemes and finish requirements

• There are specific situations where the use of a topcoat is considered mandatory - Off shore environment installation - Area of high UV exposure : chalking, color change - Areas of high moisture exposure : splash zone - Coarse sprayed finish : a stippled finish may collect airborne contaminants

• It is recommended that Chartek is tipcoated when it is sufficiently cured and the surfaces are clean and dry

Top Coat

Final Condition

Chartek Application Training

Documents

Transcript of Chartek Application Training